LEAN SYSTEM ENGINEERING

1. KIOT
Lean system engineering
Target group: 3rd year GED
Chapter four
Standardized work
“Establishing World Class Manufacturing Practices”
By: Endashaw Yohannes
Kombolcha/Ethiopia
April , 2019
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2. The Challenge of Change
 Comfort
 Fear
 Anger
 Anxiety
 Sabotage
 Loss of
status
 Denial
 Blame
 Past Patterns
WIIFM?
(What’s in it for me?)
“…no meaningful
change occurs
without chaos”
Margaret Wheatley
Chaos
Reject Accept
Where we are Where we want to be
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3. “Improvement is endless and eternal.”
Toyota Proverb
 Standardized work is the safest, easiest, and most
effective way of doing the job.
 Standardized work is a tool for developing,
confirming, and improving our method (processes).
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4.  A process is simply a set of steps or actions with a
clearly defined goal.
 The process tells the team member what to do, when
to do it, and in what order.
 Method is the mix of man/woman, machine, and
material.
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5. Overview of Standard Work
Used as a tool, standard work accomplishes the following:
• It establishes a routine for repetitive tasks.
• It makes managing resource allocation and scheduling easier.
• It establishes a relationship between a person and the
environment (both the machine and materials).
• It provides a basis for improvement
• It prohibits backsliding, or relapse into previous bad habits.
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6. Standardized Work
Objectives
 Establish and clarify the guidelines for manufacturing
 QUALITY, QUANTITY, COST, INVENTORY, AND SAFETY
 Provide a tool for Kaizen
 YOU CANNOT MANAGE WHAT YOU DO NOT MEASURE
 WHERE THERE IS NO STANDARD, THERE CAN BE NO
KAIZEN
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8. A
Advantages of Standard
Work
 Repeatable Processes.
 Operator Training.
 Repeatable Quality
 Improved Safety.
Disadvantages of
Standard Work
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9. Why Standardized Work?
• Standardized work provides great benefits:
1. Process stability: Stability means repeatability. We need to meet our
productivity, quality, cost, lead time, safety, and environmental targets
every time.
2. Clear stop and start points for each process:
• These and knowledge of our takt, that is, our pace of production
rationalized with our rate of sales and cycle times, allow us to see
our production condition at a glance.
oAre we ahead or behind?
o Is there a problem?
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10. 3. Organizational learning: Standardized work preserves know-how and
expertise.
• If a veteran employee leaves, we won’t lose his or her experience.
4. Audit and problem solving: Standardized work allows us to assess our current
condition and identify problems.
• Checkpoints and vital process steps are easy to track. We are able to ask
important questions:
a. Are team members able to do the process smoothly or are they falling
behind?
b. If they are falling behind, by how much and in what job elements?
c. How can we improve these elements?
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11. 5. Employee involvement and poka-yoke:
o In the Lean system team members develop standardized
work, supported by supervisors and engineers.
o Moreover, team members identify opportunities for simple,
inexpensive error-proofing or poka-yoke devices.
6. Kaizen: Our processes are mainly muda.
o Once we have achieved process stability, we are ready to
improve.
o Standardized work provides the baseline against which we
measure improvement
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12. 7. Training: Standardized work provides a basis for employee
training.
a. Once operators are familiar with standardized work formats, it
becomes second nature for them to do the job according to
standards.
b. Vital steps and checkpoints serve as constant reminders.
• Because process training is easier, we can more easily respond
to changes in demand (and the corresponding changes in takt
time and process steps).
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13. Steps to Create Standard Work
 Evaluate the current situation
 Identify areas of opportunity
 Modify the existing process
 Quantify improvements
 Implement new standard work
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14. Standardized Work
Three elements
o “Takt” time / Cycle time
o Work Sequence
o Standard WIP
Four Tools
o Time Observation
o Process Capacity
o Standard Work Combination Sheet
o Standard Work Layout
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15. 1. Takt Time
• Takt time is how frequently a product must be completed to
meet customers’ expectations. It is calculated using customer
demand and available time.
• Takt time sets the rhythm for standard work.
• Operator cycle time (CTO) is the total time required for an
operator to complete one cycle of operation, including time
needed for
o Walking,
o Loading and unloading, and
o Inspecting products.
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16. Takt Time cont...
o The machine cycle time (CTm) is the time between the instant an operator
presses the “on” or “start” button and the point at which the machine
returns to its original position after completing the target operation.
o Takt time is equal to the total daily operating time divided by the total
daily requirements.
o The variables include customer demand and available work time.
o Therefore, you should recalculate takt time when your customer demand
available work time changes.
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17. Takt time cont...
• The total cycle time (TCT) is the rate of completion of a process or
operation.
• This is a summation of operator cycle time and machine cycle time for all
processes in the operation.
• Where i is the machine number and n is the total number of machines.
• If takt time is known, computing TCT will provide an understanding of
how many operators may be needed for line balancing needs.
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18. 2. Work Sequence
• The work sequence defines the order in which the work is
done in a given process. For example, the team member
might have to
o Pick up the part
o Walk to the machine
o Place the part in the machine and process the part
o Take the part to the next machine
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19. 2. Work Sequence cont..
• We have to clearly define the best way to do each job action
and the proper sequence. possible, used pictures and
drawings to show
 Proper posture
 How the hands and feet should move
 How to hold the tools
 Accumulated know-how or the ins and outs of the job
 Critical quality or safety item
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20. 3. In-Process Stock
o In-process stock is the minimum number of unfinished work
pieces required for the operator to complete the process
without standing in front of a machine.
o The determining factor is that work cannot progress without a
certain number of pieces on hand.
o Defining in-process stock establishes work-in-process (WIP)
standards per process and, again, makes abnormalities obvious.
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21. Charts Used to Define Standardized
Work
• Three charts are used to define standardized
works are
1. Production capacity chart
2. Standardized work combination table
3. Standardized work analysis chart
• Each is a tool for analyzing and defining a
process and for identifying improvement points.
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1. Production Capacity Chart
oThis chart determines the capacity of the machines in a process.
o It documents machine and manual times and allows us to
identify bottlenecks at a glance.
oProduction capacity for a given machine is calculated using the
following formula:
oCapacity = Operational time per shift ÷ (Process time + Setup
time/interval)

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1. Production Capacity Chart cont...
o Setup time refers to the time required to change from one
machine setting to another.
o Setup for a bobbin thread might include winding bobbin
thread, adjusting with bobbin case, and replacing bobbin to
machine
o The interval refers to the frequency of setup in terms of
number of parts.

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The production capacity of the sewing machine used in process 2
may be calculated as follows:
a) Operational time = 460 minutes per shift (27,600 seconds)
b) Process time = 24 seconds per part
c) Time needed to replace bobbin= 60 seconds
d) Interval = every 300 parts
Solution: Capacity = 27,600 seconds ÷ (24 + 60/300) = 1,140.5 parts
oThe capacity of the sewing machine is 1,141 parts per shift.

25. 5/7/2019 25Figure 4.2 Production capacity chart.

26. 2. Standardized Work Combination
Table
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• This chart shows
• Work elements and their sequence
• Time per work element
• Operator and machine time
• The interaction between operators and machines or
between different operators
• The chart makes kaizen easier by breaking down the movements
of the operator and relating them to machine time.

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Figure 4.3 Standardized work combination table.

28. 3. Standardized Work Analysis
Chart
• This chart helps to rationalize layout and to
train workers. It comprises
 Work layout
 Process steps and times
 Critical quality and safety items
 Standardized WIP stock
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29. 5/7/2019 29Figure 4.4shows an actual chart.

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Standardized Work and Kaizen
o Standardized work is a process whose goal is kaizen. If
standardized work doesn’t change, we are regressing.
o The leader’s responsibility is to maintain a good condition and
to improve.
o Sometimes kaizen opportunities are obvious.
•These include obvious muda such as recurring defects,
machine breakdowns, or excessive WIP.
•Hard-to-do work (muri) or unevenness (mura) are other
obvious targets.

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Standardized Work and Kaizen
Cont...
oThe following sections describe design guidelines that can
help us find kaizen opportunities.
 Guidelines for Layout and Equipment
 Guidelines for Economy of Motion
 Guidelines for Tools and Jigs

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A. Guidelines for Economy of Motion
o Hand movements should be symmetrical and concurrent.
o Light work should be done with the hands rather than the upper
arms and shoulders.
o Motion should flow freely.
o Work should be done in the “strong circle” a yard in diameter and
directly in front of the worker. Maintain appropriate body posture.
o Keep hands free as much as possible.

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B. Guidelines for Layout and Equipment
o Identify home positions for tools and materials.
o Build flexibility into the layout to accommodate demand
changes and taller or shorter operators.
o Move parts horizontally. Avoid vertical part movement.
o Use gravity to move parts (e.g., with sloping parts racks).
o Place tools and materials conveniently.
o Ensure adequate lighting.
o Use colors.
o Use U-shaped layouts so that process start and end points are
side by side.

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C. Guidelines for Tools and Jigs
 Develop jigs to eliminate manual holding of materials.
 Use ergonomic tools
(i.e., tools that are easy to grip, encourage good hand/wrist posture,
and minimize forces and vibration).
 Combine tools where possible
(e.g., use a T-wrench instead of a socket wrench and screwdriver).
 Where possible, use balancers that automatically withdraw the tool
from point of use.

35. Questions
355/7/2019

36. Group Assignment
1. Discussion on lean six sigma tools
NB: maximum weight (20 mark)
Submission date : may 17, 2019
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